Cut resistant fabric

ABSTRACT

A cut resistant fabric and a method of manufacturing a cut resistant fiber is disclosed herein. The fabric comprises a Ultra High Molecular Weight Polyethylene (UHMWPE) material and a sheet shaped wollastonite filler. The sheet shaped wollastonite filler is treated with a coupling agent and mixed with the UHMWPE material. A thickness of the sheet shaped wollastonite filler is less than 10 micrometers (μm). The method comprises providing the sheet shaped wollastonite filler having a thickness of less than 10 μm and treating the sheet shaped wollastonite filler with a coupling agent at a first predefined temperature to obtain a uniform solution. The method further comprises mixing the uniform solution with a fiber solution comprising UHMWPE resin at a second predefined temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of foreign ChinesePatent Application No. 202110147256.5, filed on Feb. 3, 2021 with theChina National Intellectual Property Administration and entitled “CUTRESISTANT FABRIC,” which is incorporated herein by reference in itsentirety.

TECHNOLOGICAL FIELD

Example embodiments of the present disclosure relate generally to a cutresistant fabric, and more particularly, to a cut resistant fabrichaving Ultra High Molecular Weight Polyethylene (UHMWPE) resin.

BACKGROUND

Cut resistant fabrics provide cut protection, tear and abrasionresistance against sharp or jagged objects and are widely used invarious applications. The applications range from making protectiveclothing, industrial gloves, helmets, to high strength ropes, andpackaging metal and glass articles. Such cut resistant fabrics arecomposed of polymeric and non-polymeric fibers, such as high tenacitypolyester, nylon, and gel spun fibers, and thermoplastic polyethylenefibers, such as Ultra High Molecular Weight Polyethylene (UHMWPE)fibers.

For manufacturing a cut resistant fabric, the polymeric andnon-polymeric fibers and the polyethylene fibers are treated withfillers and combined with raw materials in a spinning process to obtaincut resistant fibers. The cut resistant fibers are woven or knitted toobtain the cut resistant fabric.

The Applicant has identified several technical challenges associatedwith the cut resistant fabric comprising UHMWPE fiber. Through appliedeffort, ingenuity, and innovation, many of these identified challengeshave been overcome by developing solutions that are included inembodiments of the present disclosure, many examples of which aredescribed in detail herein.

BRIEF SUMMARY

The illustrative embodiments of the present disclosure relate to a cutresistant fabric used for manufacturing industrial gloves having highcut resistance and wear comfort for users. The cut resistant fabriccomprises an Ultra High Molecular Weight Polyethylene (UHMWPE) material,such as UHMWPE fibers or a UHMWPE resin, and a sheet shaped wollastonitefiller. The sheet shaped wollastonite filler is treated with a couplingagent and mixed with the UHMWPE material. The sheet shaped wollastonitefiller has a thickness of less than 10 micrometers (μm).

In some embodiments, the sheet shaped wollastonite filler has a lengthless than 100 μm and a width less than 50 μm.

In some embodiments, the sheet shaped wollastonite filler has a Mohshardness higher than 4.5, and a silica content higher than 50%.

In some embodiments, the coupling agent comprises at least one ofgamma-Aminopropyltriethoxysilane (KH550), and polyorganosiloxane(Penta-1006).

In an example embodiment, a proportion of the sheet shaped wollastonitefiller in the cut resistant fabric ranges from 2.5% to 5% by volume.

In an example embodiment, a method for preparing a cut resistant fiberis provided. The method comprises providing a sheet shaped wollastonitefiller having a thickness of less than 10 μm. The method comprisestreating the sheet shaped wollastonite filler with a coupling agent at afirst predefined temperature to obtain a uniform solution and mixing theuniform solution with a fiber solution comprising UHMWPE resin at asecond predefined temperature.

In an example embodiment, obtaining the uniform solution comprisesmixing a dispersing agent with the sheet shaped wollastonite filler toobtain a mixture of the dispersing agent and the sheet shapedwollastonite filler and adding the mixture of the dispersing agent andthe sheet shaped wollastonite filler to a white oil. The white oil beinga fiber spinning solvent.

In some embodiments, the sheet shaped wollastonite filler has a lengthless than 100 μm, and a width less than 50 μm.

In an example embodiment, the first predefined temperature is 80°Celsius (C) and the second predefined temperature is 140° C.

In an example embodiment, the coupling agent comprises at least one ofgamma-Aminopropyltriethoxysilane (KH550), and polyorganosiloxane(Penta-1006).

The above summary is provided merely for purposes of summarizing someexample embodiments to provide a basic understanding of some aspects ofthe disclosure. Accordingly, it will be appreciated that theabove-described embodiments are merely examples and should not beconstrued to narrow the scope or spirit of the disclosure in any way. Itwill be appreciated that the scope of the disclosure encompasses manypotential embodiments in addition to those here summarized, some ofwhich will be further described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The description of the illustrative embodiments can be read inconjunction with the accompanying figures. It will be appreciated thatfor simplicity and clarity of illustration, elements illustrated in thefigures have not necessarily been drawn to scale. For example, thedimensions of some of the elements are exaggerated relative to otherelements. Embodiments incorporating teachings of the present disclosureare shown and described with respect to the figures presented herein, inwhich:

FIG. 1 illustrates an assembly line for manufacturing a cut resistantfabric, in accordance with an example embodiment of the presentdisclosure;

FIGS. 2A and 2B are views of a sheet shaped wollastonite filler, inaccordance with an example embodiment of the present disclosure; and

FIG. 3 is a flow chart illustrating a method for manufacturing a fiber,in accordance with an example embodiment of the present disclosure.

DETAILED DESCRIPTION

Some embodiments of the present disclosure will now be described morefully hereinafter with reference to the accompanying drawings, in whichsome, but not all embodiments are shown. Indeed, the disclosure may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. The terms “or” and “optionally” are used herein in boththe alternative and conjunctive sense, unless otherwise indicated. Theterms “illustrative” and “exemplary” are used to be examples with noindication of quality level. Like numbers refer to like elementsthroughout.

Fabrics used for various industrial applications, such as industrialgloves, high strength ropes, packaging glass and metal articles andpersonal protective equipment have high strength, durability and cutresistance. The fabrics are generally made of polyester fibers orpolyethylene fibers including Ultra High Molecular Weight Polyethylene(UHMWPE) fibers that provide strength, and flexibility to the fabrics.Such cut resistant fabrics are typically manufactured using compositeyarns that include the UHMWPE fibers blended with other materials forhardness of the fabrics. For instance, the UHMWPE fibers are mixed withglass fibers to achieve high cut resistance levels. The UHMWPE fibersare also blended with rod-shaped hard fillers for example, short fibersor nano rods during a spinning process. For many applications, theUHMWPE fibers are also mixed with stainless-steel material to achieve apredetermined hardness for the fabrics.

However, blending the UHMWPE fibers with glass fibers, rod-shaped fibersor stainless-steel material make the fabrics brittle and cause thefabrics to crack or break during manufacturing and use by a user. Thebreaking of the fabrics during manufacturing, on many instances, causesdamage to a manufacturing equipment resulting in increased cost.Industrial gloves made from such fabrics are generally uncomfortable inwearing and cause allergy to the user. Further, manufacturing thefabrics with such composite yarns is time-consuming and complex.

Various example embodiments described in the present disclosure relateto a cut resistant fabric that is hard, flexible and provides wearcomfort to users. The cut resistant fabric is composed of UHMWPE resinand a filler, for instance, a sheet shaped wollastonite filler. TheUHMWPE resin are combined with the sheet shaped wollastonite filler inthe spinning process at a predefined temperature to obtain the cutresistant fabric. The sheet shaped wollastonite filler has a predefineddimension, such as a sheet shape, and a thickness less than 10micrometers (μm). The sheet shaped wollastonite filler has a length lessthan 100 μm and a width less than 50 μm. The sheet shaped wollastonitefiller has a Mohs hardness, which is indicative of scratch resistance ofa surface, higher than 4.5 and a silica content higher than 50% byvolume. In an example, the thickness of the sheet shaped wollastonitefiller is selected to be lower than the thickness of the UHMWPE fibersto allow mixing of the filler with the UHMWPE resin.

The predefined dimension allows an anisotropic arrangement of the sheetshaped wollastonite filler with the UHMWPE resin that facilitates evendistribution and mixture of the filler with the UHMWPE resin. Further,the sheet shaped wollastonite filler reduces breakage in the fabric byreducing overall stress distribution of the UHMWPE resin duringmanufacturing or knitting and improves shear strength of the fabric. Thesheet shaped wollastonite filler shows improved mixing with other rawmaterials during the spinning process and glove manufacturing.

In an example embodiment, prior to mixing with the UHMWPE resin, thesheet shaped wollastonite filler is treated with a coupling agent, forinstance a silane coupling agent. The silane coupling agent providesimproved bonding and compatibility between the filler and the UHMWPEresin.

The fabric comprising the UHMWPE resin and the sheet shaped wollastonitefiller exhibits flexibility and strength and is used for variousapplications, such as glove knitting, industrial ropes and handlingglass and metal articles. The fabric is also light-weighted and findsapplication in armor design, such as vehicle armor and protectivehelmets and vests.

The details regarding manufacturing of the fabric using an assembly linesystem is described with reference to subsequent figures anddescription.

The components illustrated in the figures represent components that mayor may not be present in various example embodiments described hereinsuch that embodiments may include fewer or more components than thoseshown in the figures while not departing from the scope of thedisclosure.

Turning now to the drawings, the detailed description set forth below inconnection with the appended drawings is intended as a description ofvarious example configurations and is not intended to represent the onlyconfigurations in which the concepts described herein may be practiced.The detailed description includes specific details for the purpose ofproviding a thorough understanding of various concepts with likenumerals denoting like components throughout the several views. However,it will be apparent to those skilled in the art of the presentdisclosure that these concepts may be practiced without these specificdetails.

FIG. 1 illustrates an assembly line 100 for manufacturing a cutresistant fabric in accordance with an example embodiment of the presentdisclosure. As shown in FIG. 1 , the assembly line 100 comprises acontinuous extruder 102 having a hopper or an inlet 104, an extruder die106, a metering pump 108, a spinneret 110, a quenching and extractionbath 112, an oven 114, and a roller 116.

In an example, the extruder die 106 comprises a mandrel 118 disposedconcentrically to the extruder die 106 within the extruder die 106, andan extrusion screw 120 disposed on the mandrel 118. The mandrel 118 isrotatable along an axis within the extruder die 106. In an exampleembodiment, the continuous extruder 102 comprises multiple heaters (notshown in the figure) placed on an inner surface of the extruder die 106to heat materials fed to the continuous extruder 102. The extruder die106 has outlets 122-1 and 122-2 and each of the outlets 122-1 and 122-2is coupled to the metering pump 108. An outlet of the metering pump 108is coupled to the spinneret 110. Although FIG. 1 illustrates a singlespinneret 110 coupled to the metering pump 108, in various otherembodiments there may be multiple spinnerets, each spinneret beingcoupled to the metering pump 108. The assembly line 100 is arranged suchthat the spinneret 110 is coupled to the quenching and extraction bath112 and the quenching and extraction bath 112 is coupled to the oven114. The assembly line 100 comprises the roller 116 positioned adjacentto the oven 114.

For manufacturing a cut resistant fabric, an Ultra High Molecular WeightPolyethylene (UHMWPE) material, such as UHMWPE fibers or a UHMWPE resinof a specific dimension or a particle size are dissolved into a fiberspinning solvent. The UHMWPE resin may be in form of either granules,pellets or a powder. In an example embodiment, the UHMWPE resin, in apowdered form, is dissolved into the fiber spinning solvent. Theparticle size of the UHMWPE resin is within a range from 80 μm to 200 μmand molecular weight is in a range from 1×10⁶ to 8×10⁶. The fiberspinning solvent, for instance, is a white oil or a paraffin oil. Afterdissolving the UHMWPE resin in the fiber spinning solvent, a fibersolution is obtained. The fiber solution has a consistent viscosity. Thefiber solution is fed to the continuous extruder 102 via the inlet 104.

In an example, a filler, for instance a sheet shaped wollastonite filleris treated with a silane coupling agent, prior to mixing the filler withthe fiber solution. The sheet shaped wollastonite filler is illustratedin FIGS. 2A and 2B in accordance with an example embodiment of thepresent disclosure. FIGS. 2A and 2B show a microscopic view of thecomposition and structure of the sheet shaped wollastonite filler. FIG.2A shows a lower resolution view 202 of the composition and structure ofthe sheet shaped wollastonite filler and FIG. 2B shows a higherresolution view 204 of the sheet shaped wollastonite filler.

The sheet shaped wollastonite filler has a predefined dimension having athickness of less than 10 micrometers (μm), a length of less than 100μm, and a width of less than 50 μm. The thickness of the sheet shapedwollastonite filler is selected such that the sheet shaped wollastonitefiller can be properly mixed with the UHMWPE fibers. Further, the sheetshaped wollastonite filler has a Mohs hardness higher than 4.5, and asilica content higher than 50% by volume. The Mohs hardness of 4.5 orhigher provides a predetermined hardness to the fabric for manufacturingcut resistant fabrics. Such hardness improves shear modulus ofconstituent fibers thereby increasing the shear strength of the fabrics.The sheet shaped wollastonite filler having the predefined dimensionprovides an anisotropic arrangement of the filler with the UHMWPE resin.Such an arrangement provides improved strength to the cut resistantfabric and reduces breakage and stress distribution of fibers during thespinning process.

The silane coupling agent is one of a gamma-Aminopropyltriethoxysilane(KH550) agent, and a polyorganosiloxane (Penta-1006) agent. Treating thesheet shaped wollastonite filler with the silane coupling agent improvescompatibility and interfacing between the sheet shaped wollastonitefiller and the UHMWPE resin.

Referring to FIG. 1 , a uniform solution is obtained by mixing the sheetshaped wollastonite filler and the silane coupling agent. A dispersingagent is also added to the uniform solution to improve stability of theuniform solution and surface compatibility of the sheet shapedwollastonite filler and the silane coupling agent. In an example, acontent of the dispersing agent within the uniform solution is in arange of 0.03% to 0.5% by volume. The uniform solution is fed to thecontinuous extruder 102 via the inlet 104. The uniform solution havingthe sheet shaped wollastonite filler and the silane coupling agent ismixed and blended with the fiber solution comprising the UHMWPE resinand the fiber spinning solvent in the continuous extruder 102.

In operation, the mandrel 118 and the extrusion screw 120 of thecontinuous extruder 102 rotate to blend the fiber solution and theuniform solution. The mixing and blending is performed in a continuousmanner based on the rotation and a mixture of the fiber solution and theuniform solution is being pushed towards the outlets 122-1 and 122-2 ofthe continuous extruder 102. In an example, the heaters (not shown inthe figure) disposed within the inner surface of the extruder die 106heat the mixture to a temperature, for instance, 80° Celsius (° C.) forcoherent blending. In an example, the mixture is blended and heated at80° C. for two hours in the extruder die 106.

The mixture, after the blending, is supplied to the metering pump 108via the outlets 122-1 and 122-2 of the extruder die 106. In an example,the outlets 122-1 and 122-2 have narrower tubes than the extruder die106 and some pressure is applied to the mixture to reach the meteringpump 108 via the outlets 122-1 and 122-2. In an example, the meteringpump 108 segregates the mixture into two or more portions and supplieseach portion of the mixture to a spinneret, such as the spinneret 110.In an example embodiment having the multiple spinnerets coupled to themetering pump 108, each spinneret receives a portion of the mixture fromthe metering pump 108.

At the spinneret 110, the mixture is filtered to remove impurities fromthe mixture and then supplied to the quenching and extraction bath 112.The mixture is delivered to water pipes disposed within the quenchingand extraction bath 112 to lower the temperature of the mixture and forma gel. The gel comprises solvents, such a paraffin oil and othersolvent, such as xylene. After the gel passes through the water pipesand before entering the oven 114, the xylene is extracted from the gelto lower a paraffin content in the gel. Thereafter, at the oven 114, thegel is heated at a high temperature, for instance, 140° C. for dryingthe gel to remove the paraffin content. A drawing operation of fibers isperformed through the roller 116. In various example embodiments, thedrawing operation is performed, at a draw ratio of 35. Towards the endof the drawing operation, a yarn 124 of fibers is obtained. The fibersobtained have high cut and abrasion resistance property and are woven orknitted to obtain the cut resistant fabric. In various exampleembodiments, the fibers have cut resistance to achieve European EN3882016 Level C or American Society for Testing and Materials (ASTM) F2292A3 level and are suitable for manufacturing 13-gauge industrial gloves.

FIG. 3 is a flow chart illustrating a method 300 for manufacturing a cutresistant fiber in accordance with an example embodiment of the presentdisclosure. Referring now to block 302, the method of manufacturing thecut resistant fiber comprises providing a sheet shaped wollastonitefiller having a thickness of less than 10 micrometers (μm). The sheetshaped wollastonite filler provides hardness to the fiber and reducesbreakage in the fiber during manufacturing. At block 304, the sheetshaped wollastonite filler is treated with a coupling agent at a firstpredefined temperature to obtain a uniform solution. In an exampleembodiment, the coupling agent is a silane coupling agent, such as oneof a gamma-Aminopropyltriethoxysilane (KH550) agent, and apolyorganosiloxane (Penta-1006) agent. The first predefined temperatureis 80° C.

At block 306, the method for manufacturing the cut resistant fibercomprises mixing the uniform solution with an Ultra High MolecularWeight Polyethylene (UHMWPE) resin at a second predefined temperature.The second predefined temperature is 140° C. The uniform solution isobtained by mixing a dispersing agent with the sheet shaped wollastonitefiller and adding a fiber spinning solvent, such as the white oil. In anexample, the sheet shaped wollastonite filler has a length less than 100μm, and a width less than 50 μm.

In an example embodiment, the cut resistant fiber is obtained by mixingthe fiber solution comprising the UHMWPE resin and the uniform solution,where the sheet shaped wollastonite filler has a thickness of 0.5 μm, alength of 8 μm and a width of 7 μm. In such a cut resistant fiber, acontent of the sheet shaped wollastonite filler is 2.5% by volume. Forthe cut resistant fiber, a hot drawing temperature is 140° C. and thedrawing ratio is 50.

In another example embodiment, the cut resistant fiber is obtained bymixing the fiber solution comprising the UHMWPE resin and the uniformsolution, where the sheet shaped wollastonite filler has a thickness of3 μm, a length of 20 μm and a width of 10 μm. The hot drawingtemperature is 140° C. and the drawing ratio is 35. The content of thesheet shaped wollastonite filler in the fiber is 5% by volume. A higherpercentage of the sheet shaped wollastonite filler in the fiber isindicative of more toughness and higher cut resistance of the fiber. Forinstance, the fiber having 5% sheet shaped wollastonite filler has ahigher cut resistance than the fiber having 2.5% sheet shapedwollastonite filler and can reach a level C or higher in cut resistance.

It must be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the content clearly dictates otherwise.

References within the specification to “one embodiment,” “anembodiment,” “embodiments”, or “one or more embodiments” are intended toindicate that a particular feature, structure, or characteristicdescribed in connection with the embodiment is included in at least oneembodiment of the present disclosure. The appearance of such phrases invarious places within the specification are not necessarily allreferring to the same embodiment, nor are separate or alternativeembodiments mutually exclusive of other embodiments. Further, variousfeatures are described which may be exhibited by some embodiments andnot by others. Similarly, various requirements are described which maybe requirements for some embodiments, but not other embodiments.

It should be noted that, when employed in the present disclosure, theterms “comprises,” “comprising,” and other derivatives from the rootterm “comprise” are intended to be open-ended terms that specify thepresence of any stated features, elements, integers, steps, orcomponents, and are not intended to preclude the presence or addition ofone or more other features, elements, integers, steps, components, orgroups thereof.

As required, detailed embodiments of the present disclosure aredisclosed herein; however, it is to be understood that the disclosedembodiments are merely exemplary, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the present disclosure in virtually anyappropriately detailed structure.

While it is apparent that the illustrative embodiments herein disclosedfulfill the objectives stated above, it will be appreciated thatnumerous modifications and other embodiments may be devised by one ofordinary skill in the art. Accordingly, it will be understood that theappended claims are intended to cover all such modifications andembodiments, which come within the spirit and scope of the presentdisclosure.

What is claimed is:
 1. A method for preparing a cut resistant fiber,comprising: providing a sheet shaped wollastonite filler having athickness of less than 10 micrometers (μm); treating the sheet shapedwollastonite filler with a coupling agent at a first predefinedtemperature to obtain a uniform solution; and mixing the uniformsolution with a fiber solution comprising Ultra-High Molecular WeightPolyethylene (UHMWPE) resin at a second predefined temperature.
 2. Themethod of claim 1, wherein obtaining the uniform solution comprises:mixing a dispersing agent with the sheet shaped wollastonite filler toobtain a mixture of the disperse agent and the sheet shaped wollastonitefiller; and adding the mixture of the dispersing agent and the sheetshaped wollastonite filler to a white oil, wherein the white oil is afiber spinning solvent.
 3. The method of claim 1, wherein the sheetshaped wollastonite filler has a length less than 100 μm, and a widthless than 50 μm.
 4. The method of claim 1, wherein the first predefinedtemperature is 80° Celsius (C) and the second predefined temperature is140° C.
 5. The method of claim 1, wherein the coupling agent comprisesat least one of gamma-Aminopropyltriethoxysilane (KH550), andpolyorganosiloxane (Penta-1006).